At Woodruff Engineering, we specialise in turning ambitious ideas into precision-engineered systems. Our latest project – a Large Racetrack Helmholtz Coil, capable of 2MW pulsed peak power and generating 3 kilogauss (3000 Gauss) – marks the largest magnet we’ve ever built. Measuring 15 ft long, 4 ft wide, and 6 ft high, this system demonstrates not only scale, but also the depth of our design-to-delivery expertise.
It’s a milestone project that encapsulates our full-spectrum custom design service, guiding clients from initial concept to fabrication-ready engineering under our ISO 9001:2015 quality management system.
The Challenge: Turning an idea into a High-Power Magnet
The client approached us with a bold idea: a megawatt-level pulsed magnet system that could deliver intense magnetic fields with strict power, cooling, and interfacing requirements. What started as a sketch of a racetrack-shaped magnet soon evolved into a complex project requiring advanced simulation, precision engineering, and collaborative problem-solving.
Using our Custom Design Service, we developed a tailored solution to meet the client’s needs, incorporating:
- Magnetic field simulations
- Thermal and stress analysis
- Initial layout and configuration options
This early stage enabled the client to test concepts, evaluate costs, and refine performance expectations before committing to a final design.
The Process: From Concept to Reality
Every custom magnet project at Woodruff Engineering follows a proven workflow:
- Gathering requirements
We work closely with the client to define:
- Target magnetic field strength
- Uniformity (typically ±5%, with ±1% or better possible at higher cost/size)
- Uniformity region diameter
- AC or DC operation (DC is generally lower cost)
- Number of axes
- Pulse length (continuous vs pulsed duty cycles)
- Geometry limits (outer/inner coil diameter, total height, etc.)
- Preliminary design and simulation
We perform electromagnetic, thermal, and stress simulations, iterating with the client to balance performance, feasibility, and budget. - Engineering Design
- Full 3D CAD model
- Detailed Bill of Materials (BOM)
- Advanced simulations validating magnetic, structural, and thermal performance
- Design Review and Manufacturing Preparation
- Engineering Design Review
- Manufacturing Design Review
- Fabrication drawings created to ISO 9001:2015 standards
- Build Support and Delivery
Our established supply chain and in-house expertise enable cost-efficient, rapid delivery.
This workflow – Concept → Design → Engineering – is a hallmark of Woodruff Engineering’s service, particularly for large, high-specification magnet systems.
Overcoming the Engineering Obstacles
Delivering a magnet of this scale meant pushing the limits of precision engineering. We encountered and resolved several key challenges:
Building a magnet of this scale required careful solutions to significant challenges:
- Electromagnetic forces: Managing large mechanical loads from megawatt-level pulses.
- Precision tolerances: Ensuring consistent magnetic field alignment across the uniformity region.
- Materials testing: Verifying resistivity, contact resistance, and long-term durability.
- Thermal management: Integrating water cooling systems to sustain operation under heavy pulsed loads.
- Client interfacing: Adapting the design to integrate seamlessly with a custom-built vessel.
- Budget control: Meeting performance targets while respecting cost constraints.
- Logistics and export: Coordinating delivery of large components under complex international trade conditions.
Each step required careful testing, documentation, and validation to ensure the finished design met the exacting standards our clients expect.
Why This Magnet Matters
The Large Racetrack Helmholtz Coil is a one-of-a-kind achievement:
- Power and scale: Operating at megawatt pulses, this magnet combines size and performance rarely achieved in custom projects.
- Adaptability: Modular design supports customization for multiple applications.
- Cooling innovation: Water cooling enables high magnetic fields in compact, power-limited environments.
The magnet is water cooled and capable of sustained high-power operation, with a modular design that makes it ideal for customization and integration into broader systems.
Applications Across Science and Industry
This magnet demonstrates the flexibility of our designs, with potential applications in:
- Fusion energy research: high-field pulsed magnets for plasma confinement and testing
- Accelerators: large dipole magnets for beam steering
- Industrial processes: magnetic field-enabled manufacturing and materials testing
- Large motors and power systems: high-current magnetic field generation
By tailoring field uniformity, pulse length, and geometry to client requirements, we ensure our systems integrate seamlessly into a variety of advanced applications.
What This Project Demonstrates About Woodruff Engineering
Delivering this system proves Woodruff Engineering’s ability to design and build fully integrated custom magnet solutions at scale.
- It was the largest magnet we have ever built, 15 ft in length and operating at megawatt-level pulses.
- We managed mechanical forces, precision tolerances, and vessel interfacing within a tight budget.
- We delivered fabrication-ready engineering under ISO 9001:2015 standards, ensuring quality and repeatability.
- Beyond the magnet itself, we design bespoke power supplies matched to coil properties, offering a complete system-level solution.
This project reinforces our position as a trusted partner for clients advancing clean energy, heavy industry, or next-generation research.
